Pallet loader workstation for manufacturing fiber optic modules

ABSTRACT

Apparatuses and methods for automating the assembly of a fiber optic module. The fiber optic module typically includes a housing, a clip, and a ferrule that is attached to the end of a fiber optic cable. The housing, clip, ferrule and fiber optic cable are supported by a pallet assembly. The pallet assembly can be loaded into a docking station of a laser weld machine that welds the ferrule to the clip. The pallet assembly includes a cartridge that is attached to a pallet and supports the housing. The pallet is constructed to receive different cartridges. Each cartridge has support features that correspond to a specific type of module housing. A different type of module housing may be loaded onto the pallet assembly by merely replacing the cartridge. The same pallet can therefore be used for the assembly of different fiber modules.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to pallets and workstations forassembling fiber optic modules.

[0003] 2. Background Information

[0004] Fiber optic networks typically contain a number of optical fibersinterconnected by various routers, computers, switches, etc. Informationis transmitted through the fibers by photo-emitters such as laserdiodes. The laser diodes emit light that travels through the fiber to aphoto-detector.

[0005] The end of an optical fiber is typically coupled to thephoto-emitter or photo-detector in an electronic package sometimesreferred to as a fiber optic module. The package typically contains aplatform that supports the emitter/detector and an outer metal housingto protect the optical components. The housing has an aperture thatreceives the end of the fiber. A metal sleeve, otherwise known as aferrule, is attached to the end of the fiber and then welded to thepackage housing, or a metal clip mounted to the housing platform. It iscritical to accurately align the fiber with the emitter/detector tominimize the optical power losses in the system.

[0006] The ferrule is typically welded to the package with one or morelasers of a laser weld machine. The laser weld machine has toolingfixtures that hold the package and ferrule in place during the weldprocess. The tooling fixtures are typically custom built for each typeof fiber optic module assembly. Producing a different type of fibermodule typically requires shutting down the assembly line and re-toolingthe workstations of the line. It would be desirable to provide toolingthat would allow for a change in fiber modules without shutting down theline.

[0007] The ferrule and fiber optic cable is inserted through a snout ofthe module housing before being welded to the clip. Inserting theferrule through the housing snout can be a time consuming processsimilar to threading a needle. It would be desirable to automate theprocess of inserting the ferrule through the housing snout to reduce thetime required to assemble the module. Additionally, it would bedesirable to further standardize and automate the process of assemblingfiber optic modules.

BRIEF SUMMARY OF THE INVENTION

[0008] A pallet assembly for assembling a fiber optic module thatincludes a housing. The assembly includes a cartridge that can supportthe housing and is attached to a pallet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a top side perspective view of a pallet assembly;

[0010]FIG. 2 is a front top perspective view of a pallet loader station;

[0011]FIG. 3 is a front perspective view of a pallet station and gripperassembly of the pallet loader station;

[0012]FIG. 4 is a rear perspective view of the gripper assembly;

[0013]FIG. 5 is a top perspective view of the gripper assembly with aloaded fiber optic cable assembly;

[0014]FIG. 6 is a top perspective view of the gripper assembly with aferrule of the fiber optic cable assembly pulled through a guide trayand secured by a gripper;

[0015]FIG. 7 is a side top perspective view of the gripper assembly withthe gripper pulled to a home position;

[0016]FIG. 8 is a front top perspective view of the pallet loaderstation with the gripper assembly moved to a load position;

[0017]FIG. 9 is an enlarged top front perspective view of the palletloader station showing the gripper assembly in the load position;

[0018]FIG. 10 is a side top perspective view showing a pneumatic gripperholding the ferrule;

[0019]FIG. 11 is a side top perspective view showing a ferrule armsecuring the ferrule;

[0020]FIG. 12 is a front top perspective view of the pallet loaderstation showing the fiber optic cable assembly loaded onto the palletassembly;

[0021]FIG. 13 is a side top perspective view of the pallet assembly witha clip loaded onto a module housing;

[0022]FIG. 14 is a side top perspective view of the pallet assemblyloaded into a docking station of a laser weld machine;

[0023]FIG. 15 is a bottom perspective view of an electrical connector ofthe docking station.

DETAILED DESCRIPTION

[0024] Disclosed are apparatuses and methods for automating the assemblyof a fiber optic module. The fiber optic module typically includes ahousing, a clip, and a ferrule that is attached to the end of a fiberoptic cable. The housing, clip, ferrule and fiber optic cable aresupported by a pallet assembly. The pallet assembly can be loaded into adocking station of a laser weld machine that welds the ferrule to theclip. The pallet assembly includes a cartridge that is attached to apallet and supports the housing. The pallet is constructed to receivedifferent cartridges. Each cartridge has support features thatcorrespond to a specific type of module housing. A different type ofmodule housing may be loaded onto the pallet assembly by merelyreplacing the cartridge. The same pallet can therefore be used for theassembly of different fiber modules. This minimizes the tooling cost andchange-over time associated with manufacturing different types ofmodules. The ferrule can be loaded into the housing with a self-aligninggripper assembly. The self-aligning process is automated to reduce thetime and cost associated with manufacturing a module. The dockingstation of the laser weld machine may have features that more fullyautomate the docking and welding processes.

[0025] Referring to the drawings more particularly by reference numbers,FIG. 1 shows a pallet assembly 10. The pallet assembly 10 may supportvarious components of a fiber optic module during assembly of themodule. The module components include a housing 12 that has a snout 14and a plurality of electrical leads 16. Such a configuration is commonlyreferred to as a “butterfly” package. A fiber optic cable assembly 18 iscoupled to the housing 12 in the assembly process. The cable assembly 18includes a fiber optic cable 20 that is attached at one end to a pair offerrules 22 and 24, and terminates at the other end with a connector 26.The ferrule 22 is typically soldered to the housing snout 14. The otherferrule 24 is welded to a clip 28 located within the housing 12.

[0026] The pallet assembly 10 includes a cartridge 30 that supports thehousing 12 and is attached to a pallet 32. The cartridge 30 includes apair of ledges 34 to support the leads 16. The pallet assembly 10 mayincludes a spring loaded swing arm assembly 36 that pushes the housing12 into a pair of stops 38 on the cartridge 30. The swing arm assembly36 may include a spring 40 that is attached to a swing arm 42 and thepallet 32. The spring 40 exerts a force through the swing arm assembly36 that biases the housing 12 into the stops 38. The swing arm assembly36 secures the housing 12 within the pallet assembly 10 in both lateral,and perpendicular directions. The stops 38 may have angled surfaces 44to compensate for tolerances in the housing 12, and also lock thehousing against the floor of cartridge 30. The spring biased swing arm42 allows housings 12 of different sizes to be loaded onto the cartridge30. The swing arm 42 also self-compensates for tolerances in thehousings 12.

[0027] The cartridge 30 can be coupled to the pallet 32 with pins 46.The dimensions of the stops 38, ledges 34, etc. of the cartridge 30 areconfigured to support a specific type of module housing 12. The palletassembly 10 can be modified to support a different type of housing 12 byreplacing the cartridge 30 with a new cartridge that is configured tosupport the different module housing. The pallet assembly 10 thusprovides a cartridge feature that allows the assembly 10 to be adaptedto various types of module housings 12, without replacing the entirepallet 32. This reduces the cost of producing the fiber module pallettooling. Without a cartridge 30 the manufacturer would have to createand store pallets for each type of module.

[0028] The pallet assembly 10 may further include a ferrule arm 48 and aclip arm 50 pivotally attached to an arm mount 52. The ferrule arm 48may include a compliant slot 54 that receives and holds the ferrule 24.The clip arm 50 may hold the clip 28 in place. The arms 48 and 50 may bemanually moved from an open position, to the closed position shown inFIG. 1. The arms 48 and 50 can hold the ferrule 24 and clip 28 during aweld process.

[0029] The pallet 32 may have a pocket 56 that supports a coiled portion58 of the fiber optic cable 20. The coiled fiber 58 may be secured by acover 60 that encloses the pocket 56. The cover 60 can be rotatedbetween open and closed positions about a pin 62. The pocket cover 60may include a finger hole 64 to facilitate opening of the cover 60.

[0030] The pallet 32 may further have a pair of channels 66 that supportportions of the fiber optic cable 20. The channels 66 and pocket 56prevent undesirable movement of the fiber optic cable 20 when the palletassembly 10 is transported to an assembly station.

[0031] The pallet assembly 10 may include a shuttle 68 that supports thecable connector 26. The shuttle 68 is coupled to the pallet 32 by ascrew 70 located within slot 72. The shuttle 68 can slide relative tothe pallet 32 to allow automatic loading of the connector 26 to aphotodetector (not shown). The pallet 32 may further have alignmentapertures 74 to allow alignment with a docking station.

[0032]FIGS. 2 and 3 show a pallet loader station 80 for loading thefiber optic cable assembly 18 onto the pallet assembly 10. The palletloader station 80 includes a pallet station 82 and a gripper assembly84. The pallet station 82 may include a camera 86 that is coupled to amonitor 88. The camera 86 and monitor 88 allow an operator to view theloading process. The pallet station 82 and gripper assembly 84 may bemounted on a table 90 which has a control panel 92 that allows anoperator to control the automated functions of the loader station 80.

[0033] The pallet station 82 may include a docking station 94 thatreceives and secures the pallet assembly 10. The station 82 may furtherinclude a pneumatic gripper assembly 96 that has a gripper 98 located atthe end of a gripper arm 100. The gripper assembly 96 may include anactuator 102 that can move the gripper 98 between open and closedpositions. The assembly 96 may further have an actuator 104 that movesthe arm 100 up and down as indicated by the arrows.

[0034] The gripper assembly 84 may slide along a guide rail 106 to andfrom the pallet station 82 as indicated by the arrows. The gripperassembly 84 is located adjacent to a fiber guide tray 108. The fiberguide tray 108 is coupled to an actuator assembly 110 that can move thetray 108 up and down as indicated by the arrows.

[0035] As shown in FIG. 4, the gripper assembly 84 may include a gripperarm 112 that extends from a base 114 that can slide along the rail 106.The base 114 and rail 106 may have dovetail features that preventtilting or rotation of the gripper assembly 84 during movement to andfrom the pallet station 82.

[0036] The gripper arm 112 may have a pair of idle rollers 116 that cansupport a fiber ferrule. The arm 112 may further have a locking arm 118which has a locking roller 120 that can secure a fiber ferrule locatedon the idle rollers 116. The locking roller 120 may have a rubber band122 that increases the friction of the roller surface. The locking arm118 can be manually pivoted about the gripper arm 112 between opened andclosed positions. The locking arm 118 may further have a rotating wheel124 that can spin the locking roller 120 and rotate the ferrule. Asupport plate 126 may extend from the support arm 112 to support a fiberoptic cable coil and connector (not shown).

[0037] The fiber guide tray 108 includes a tapered channel 128 thatextends from a guide slot 130. The channel 128 and slot 130 can be usedto align fiber ferrules with the gripper assembly 84.

[0038] The gripper assembly 84 may further include a safety handle 132to reduce the possibilities of the operator being injured by the movingtray 108. The safety handle 132 has a flag 134 that is coupled to astationary sensor 136. The sensor 136 may be an optical device thatemits a light beam (not shown). The sensor 136, and actuator assembly110 of the fiber guide tray 108 are coupled to electrical circuits (notshown) that will only allow the tray 108 to move when the gripperassembly 84 is pulled back to a home position, where the flag 134 issensed by the sensor 136 and the operator depresses the handle 132. Thetray 108 can then be moved by pushing a button on the control panel 92of the loading station 80 (see FIG. 2). Depressing the handle 132 andpushing the panel button occupies both hands and thus reduces thepossibility of the operator becoming injured by the moving tray 108.

[0039] Loading a fiber optic cable assembly onto the pallet assemblywith the loader station 80 is shown in FIGS. 512. As shown in FIG. 5 afiber optic cable assembly 18 is placed onto the support plate 126. Theconnector 26 is held by pins 138 that extend from the plate 126. Theferrules 22 and 24 are placed within the channel 128 and the fiber cable20 is placed between the idle rollers 116. The operator may then pullthe fiber cable 20 until the ferrule 22 is on top of the idle rollers116. The guide slot 130 leads and aligns the ferrule 22 with the idlerollers 116. The pallet assembly 10 may be loaded into the palletstation 82, before, after, or during this process.

[0040] As shown in FIGS. 6 and 7, the locking arm 118 is rotated to alocked position by actuating a cam lever 139. The gripper assembly 84 isthen pulled back to a home position away from the tray 108. The lockingroller 120 holds the ferrule 22 in place during movement of the gripperassembly 84 and the ferrules slide though the guide slot 130. While thegripper assembly 84 is in the home position, the operator can depressthe safety handle 132 and actuate the tray actuator assembly 110 to movethe tray 108 in a downward direction to provide clearance for theassembly 84.

[0041] As shown in FIGS. 8 and 9, the gripper assembly 84 then movesalong the rail 106 to a lock position in front of the pallet dockingstation 82. The pallet docking station 82, pallet assembly 10, gripperassembly 84 and rail 106 are configured so that further movement of theassembly 84 will push the ferrule 24 through the housing snout 14. Therail assembly 106 accurately aligns and translates the gripper assembly84 so that the ferrule 24 is automatically inserted through the housingsnout 14. This reduces the complexity and time associated with loadingthe fiber into the housing 12.

[0042] As shown in FIG. 10, the pneumatic gripper assembly 96 isactuated to lower the gripper arm 100 and allow the gripper 98 to holdthe ferrule 24. The ferrule arm 48 is then manually rotated to grasp theferrule 24 as shown in FIG. 11. The gripper 98 can then release theferrule 24 and move back to the up position. The operator can view themovement of the arm 48 through the camera 86 and monitor 88 of thestation 80 (see FIG. 2). The operator may spin the rotating wheel (notshown) to rotate the ferrule 24 to the proper orientation within thehousing 12, prior to grasping by the arm 48.

[0043] As shown in FIG. 12, the operator can release the locking roller120 by rotating locking arm 118 back and away from idle rollers 116,then slide the gripper assembly 84 back to the original position andraise the tray 108 to the up position. The cable connector 26 can beplaced onto the shuttle 68 and the pocket cover 60 may be pivoted toenclose the coiled fiber to complete the loading process within station80.

[0044] The pallet assembly 10 can then be removed from the loadingstation 80. As shown in FIG. 13, the clip 28 may be placed onto thehousing 12. The clip arm 50 may then be manually rotated to secure theclip 28.

[0045] As shown in FIG. 14, the loaded pallet assembly 10 may then beinserted into a docking station 150 of a laser weld machine. The dockingstation 150 may include a weld enclosure 152 that can be rotated ontothe cartridge 30. The weld enclosure 152 may have a window 154 thatallows one or more laser beams to weld the ferrule 24 and the clip 28.The enclosure 152 may be filled with an inert gas to facilitate thewelding process.

[0046] The enclosure 152 may include an electrical connector 156 thatcan be coupled to the leads 16 of the housing 12. As shown in FIG. 15,the electrical connector 156 may have a plurality of spring biased pins158 that make contact with the leads 16. The connector 156 provides ameans for creating simultaneous contact with all of the leads 16 of thehousing 12. The connector 156 is coupled to a tester circuit (not shown)used to align the fiber with an optical transmitter/receiver (not shown)mounted to the housing 12.

[0047] Referring to FIG. 14, the docking station 150 may further have aninductive bar 160 that can be coupled to the housing snout 14. A solderpre-form (not shown) is typically coupled to the ferrule 22 and snout14. The inductive bar 160 applies heat to the housing snout 14 to meltthe pre-form and solder the ferrule 22 to the snout 14.

[0048] The docking station 150 may further have an actuator 162 that canmove the shuttle 68 along the pallet 32. The actuator 162 can move theconnector 26 into closer proximity with an optical detector 164 used toalign the fiber with the transmitter/receiver. The docking station 150may further have alignment pins 166 that align the pallet assembly 10within the station 150.

[0049] While certain exemplary embodiments have been described and shownin the accompanying drawings, it is to be understood that suchembodiments are merely illustrative of and not restrictive on the broadinvention, and that this invention not be limited to the specificconstructions and arrangements shown and described, since various othermodifications may occur to those ordinarily skilled in the art. Forexample, although the ferrule arm 48 and clip arm 50 are described asbeing manually actuated, it is to be understood that the arms 48 and 50may be rotated by an actuator. Likewise, the locking arm 118 andtranslation of the gripper assembly 84 along the rail 106 may beautomated.

What is claimed is:
 1. A pallet assembly for assembling a fiber opticmodule that includes a housing, comprising: a pallet; and, a cartridgethat is attached to said pallet and supports the fiber optic modulehousing.
 2. The assembly of claim 1, further comprising a ferrule armcoupled to said cartridge.
 3. The assembly of claim 1, furthercomprising a clip arm coupled to said cartridge.
 4. The assembly ofclaim 1, further comprising a swing arm that pushes the fiber opticmodule housing into a stop of said cartridge.
 5. The assembly of claim4, wherein said stop has a tapered surface.
 6. The assembly of claim 1,further comprising a fiber connector shuttle that is adapted to hold afiber optic cable connector and move relative to said pallet.
 7. Theassembly of claim 1, wherein said pallet includes a fiber optic cablechannel.
 8. The assembly of claim 1, wherein said pallet includes afiber optic cable pocket.
 9. The assembly of claim 8, wherein saidpallet includes a cover that can enclose said fiber optic cable pocket.10. A pallet assembly for assembling a fiber optic module that includesa housing, a ferrule and a clip, comprising: a pallet; and, cartridgemeans for coupling the fiber optic module housing to said pallet. 11.The assembly of claim 10, further comprising ferrule means for securingthe ferrule.
 12. The assembly of claim 10, further comprising clip meansfor securing the clip.
 13. The assembly of claim 10, further comprisingbiasing means for biasing the fiber optic module housing into a stop ofsaid cartridge means.
 14. The assembly of claim 13, wherein said stophas a tapered surface.
 15. The assembly of claim 10, further comprisingshuttle means for allowing movement of a fiber optic cable connectorrelative to said pallet.
 16. The assembly of claim 10, wherein saidpallet includes a fiber optic cable channel.
 17. The assembly of claim10, wherein said pallet includes a fiber optic cable pocket.
 18. Theassembly of claim 17, wherein said pallet includes a cover that canenclose said fiber optic cable pocket.
 19. A method for loading a fiberoptic module housing onto a pallet assembly, comprising: loading a fiberoptic module onto a cartridge; and, attaching the cartridge to a pallet.20. The method of claim 19, further comprising securing a clip and aferrule.
 21. The method of claim 19, further comprising placing a fiberoptic cable connector onto a shuttle.
 22. A pallet assembly forassembling a fiber optic module that includes a housing, a ferrule and aclip, a comprising: a pallet that supports the housing; a ferrule armthat is attached to said pallet and secures the ferrule; and, a clip armthat is attached to said pallet and secures the clip.
 23. The assemblyof claim 22, further comprising a cartridge that supports the housingand is attached to said pallet.
 24. The assembly of claim 23, furthercomprising a swing arm that pushes the fiber optic module housing into astop of said cartridge.
 25. The assembly of claim 24, wherein said stopand swing arm have angled contact surfaces.
 26. The assembly of claim22, further comprising a connector shuttle that is adapted to hold afiber optic cable connector and move relative to said pallet.
 27. Theassembly of claim 22, wherein said pallet includes a fiber optic cablechannel.
 28. The assembly of claim 22, wherein said pallet includes afiber optic cable pocket.
 29. The assembly of claim 28, wherein saidpallet includes a cover that can enclose said fiber optic cable pocket.30. A pallet assembly for assembling a fiber optic module that includesa housing, a ferrule and a clip, comprising: a pallet that supports thehousing; ferrule means for securing the ferrule; and, clip means forsecuring the clip.
 31. The assembly of claim 30, further comprisingcartridge means for coupling the housing to said pallet.
 32. Theassembly of claim 31, further comprising bias means for biasing thefiber optic module housing into a stop of said cartridge means.
 33. Theassembly of claim 32, wherein said stop has an angled contact surface.34. The assembly of claim 30, further comprising shuttle means forallowing movement of a fiber optic cable connector relative to saidpallet.
 35. The assembly of claim 30, wherein said pallet includes afiber optic cable channel.
 36. The assembly of claim 30, wherein saidpallet includes a fiber optic cable pocket.
 37. The assembly of claim36, wherein said pallet includes a cover that can enclose said fiberoptic cable pocket.
 38. A method for loading components of a fiber opticmodule onto a pallet assembly housing, comprising: loading a housingonto a pallet; securing a ferrule; and, securing a clip.
 39. The methodof claim 38, further comprising placing a fiber optic cable connectoronto a shuttle.
 40. A pallet assembly for assembling a fiber opticmodule that includes a housing, comprising: a pallet; and, a cartridgethat is attached to said pallet and supports the housing, said cartridgehaving a stop; and, a swing arm that is mounted to said pallet.
 41. Theassembly of claim 40, wherein said stop and swing arm have angledcontact surfaces.
 42. The assembly of claim 40, further comprising aconnector shuttle that is adapted to hold a fiber optic cable connectorand move relative to said pallet.
 43. The assembly of claim 40, whereinsaid pallet includes a fiber optic cable channel.
 44. The assembly ofclaim 40, wherein said pallet includes a fiber optic cable pocket. 45.The assembly of claim 44, wherein said pallet includes a cover that canenclose said fiber optic cable pocket.
 46. A pallet assembly forassembling a fiber optic module that includes a housing, comprising: apallet; a cartridge that is attached to said pallet and supports thehousing, said cartridge having a stop; and, bias means for pushing thehousing into said stop.
 47. The assembly of claim 46, wherein said stopand said bias means have angled contact surfaces.
 48. The assembly ofclaim 46, further comprising shuttle means for allowing movement of afiber optic cable connector relative to said pallet.
 49. The assembly ofclaim 46, wherein said pallet includes a fiber optic cable channel. 50.The assembly of claim 46, wherein said pallet includes a fiber opticcable pocket.
 51. The assembly of claim 50, wherein said pallet includesa cover that can enclose said fiber optic cable pocket.
 52. A method forloading a fiber optic module housing onto a pallet assembly, comprising:loading a fiber optic module onto a pallet wherein the fiber opticmodule housing is pushed into a stop.
 53. The method of claim 52,further comprising placing a fiber optic cable connector onto a shuttle.54. A pallet assembly for assembling a fiber optic module that includesa housing, comprising: a pallet that supports a housing, said pallethaving a fiber optic cable pocket.
 55. The assembly of claim 54, furthercomprising a connector shuttle that is adapted to hold a fiber opticcable connector and move relative to said pallet.
 56. The assembly ofclaim 54, wherein said pallet includes a fiber optic cable channel. 57.The assembly of claim 54, wherein said pallet includes a cover that canenclose said fiber optic cable pocket.
 58. A pallet assembly forassembling a fiber optic module with a fiber optic cable, comprising: apallet having means for restraining a coiled portion of a fiber opticcable.
 59. The assembly of claim 58, further comprising shuttle meansfor allowing movement of a fiber optic cable connector relative to saidpallet.
 60. The assembly of claim 58, wherein said pallet includes afiber optic cable channel.
 61. The assembly of claim 58, wherein saidmeans includes a fiber optic cable pocket.
 62. The assembly of claim 61,wherein said means includes a cover that can enclose said fiber opticcable pocket.
 63. A method for loading a fiber optic module housing ontoa pallet assembly, comprising: loading a fiber optic module onto apallet; and, placing a fiber optic cable into a pocket of the pallet.64. The method of claim 63, further comprising placing a fiber opticcable connector onto a shuttle.
 65. A pallet assembly for assembling afiber optic module, comprising: a pallet that supports a housing, saidpallet having a fiber optic cable channel.
 66. The assembly of claim 65,further comprising a connector shuttle that is adapted to hold a fiberoptic cable connector and move relative to said pallet.
 67. A palletassembly for assembling a fiber optic module with a fiber optic cable,comprising: a pallet having means for restraining a straight portion ofa fiber optic cable.
 68. The assembly of claim 67, further comprisingshuttle means for allowing movement of a fiber optic cable connectorrelative to said pallet.
 69. A method for loading a fiber optic modulehousing onto a pallet assembly, comprising: loading a fiber optic moduleonto a pallet; and, placing a fiber optic cable into a channel of thepallet.
 70. The method of claim 69, further comprising placing a fiberoptic cable connector onto a shuttle.
 71. A pallet assembly forassembling a fiber optic module with a fiber optic cable that terminateswith a connector, comprising: a pallet that supports a housing; and, ashuttle that can move relative to said pallet and supports theconnector.
 72. A pallet assembly for assembling a fiber optic modulewith a fiber optic cable that terminates with a connector, comprising: apallet having shuttle means for allowing movement of the connector. 73.A method for loading a fiber optic module housing onto a palletassembly, comprising: loading a fiber optic module onto a pallet; and,placing a fiber optic cable connector onto a shuttle that is coupled tothe pallet.
 74. A pallet loader station for coupling a fiber optic cableand a ferrule to a fiber optic module housing, comprising: a palletstation; a rail located adjacent to said pallet station; a fiber guidetray that has a tapered channel; and, a gripper coupled to said rail andlocated adjacent to said fiber guide tray.
 75. The station of claim 74,further comprising a rotating wheel coupled to said gripper.
 76. Thestation of claim 74, further comprising an actuator coupled to saidfiber guide tray.
 77. The station of claim 74, further comprising asafety switch coupled to said gripper.
 78. The station of claim 77,further comprising a sensor that enables said safety switch when saidgripper is in a home position.
 79. A pallet loader station for couplinga fiber optic cable and a ferrule to a fiber optic module housing,comprising: a pallet station; gripper means for gripping the ferrule;tray means for aligning the ferrule with said gripper means; and,movement means for moving the gripper means to said pallet station. 80.The station of claim 79, further comprising rotating means for rotatingthe ferrule within said pallet station.
 81. The station of claim 79,further comprising actuator means for moving said tray means between anup position and a down position.
 82. The station of claim 79, furthercomprising safety means for controlling actuation of said movementmeans.
 83. A method for coupling a ferrule, attached to a fiber opticcable, to a fiber optic module housing located within a pallet station,comprising: pulling the ferrule through a guide channel of a guide tray;is gripping the ferrule; and, moving the ferrule into the pallet stationto be coupled to the fiber optic module housing.
 84. The method of claim83, further comprising moving a rotating wheel into engagement with thegripped ferrule, and rotating the wheel and spinning the ferrule whenthe ferrule is in the pallet station.
 85. The method of claim 83,further comprising deactivating a safety switch before moving theferrule into the pallet station.
 86. The method of claim 83, furthercomprising moving the guide tray to a down position before moving thegripped ferrule into the pallet station.
 87. A docking station for apallet assembly that supports a fiber optic module which has a housing,a ferrule and a clip, the pallet assembly having a shuttle that supportsa fiber optic cable connector, the housing having a plurality ofelectrical leads, comprising: an optical detector; and, an actuator thatmoves the shuttle toward said optical detector.
 88. The station of claim87, further comprising an electrical connector assembly that engages theleads of the housing.
 89. The station of claim 88, wherein saidelectrical connector assembly includes a plurality of spring biasesballs.
 90. The station of claim 87, further comprising an inductive barthat heats a portion of the housing.
 91. A docking station for a palletassembly that supports a fiber optic module which has a housing, aferrule and a clip, the pallet assembly having a shuttle that supports afiber optic cable connector, the housing having a plurality ofelectrical leads, comprising: an optical detector; and, actuator meansfor moving the shuttle toward said optical detector.
 92. The station ofclaim 91, further comprising connector means for coupling to all of theleads of the housing.
 93. The station of claim 92, wherein saidelectrical connector means includes a plurality of spring biases balls.94. The station of claim 91, further comprising an inductive bar thatheats a portion of the housing.
 95. A method for docking a palletassembly that supports a fiber optic module which has a housing, aferrule and a clip, the pallet assembly having a shuttle that supports afiber optic cable connector, the housing having a plurality ofelectrical leads, comprising: moving the shuttle toward an opticaldetector.
 96. A docking station for a pallet assembly that supports afiber optic module which has a housing, a ferrule and a clip, the palletassembly having a shuttle that supports a fiber optic cable connector,the housing having a plurality of electrical leads, comprising: anelectrical connector assembly that engages all of the leads of thehousing.
 97. The station of claim 96, wherein said electrical connectorassembly includes a plurality of spring biases balls.
 98. The station ofclaim 96, further comprising an inductive bar that heats a portion ofthe housing.
 99. A docking station for a pallet assembly that supports afiber optic module which has a housing, a ferrule and a clip, the palletassembly having a shuttle that supports a fiber optic cable connector,the housing having a plurality of electrical leads, comprising: meansfor electrically coupling to all of the leads of the housing.
 100. Thestation of claim 99, wherein said means includes a plurality of springbiases balls.
 101. The station of claim 99, further comprising aninductive bar that heats a portion of the housing.
 102. A method fordocking a pallet assembly that supports a fiber optic module which has ahousing, a ferrule and a clip, the pallet assembly having a shuttle thatsupports a fiber optic cable connector, the housing having a pluralityof electrical leads, comprising: coupling all of the leads of thehousing to a tester circuit.